2003 YAMAHA TMAX spark plugs

PERIODIC MAINTENANCE AND MINOR REPAIR
Owner’s tool kit ......................................................6-1
Periodic maintenance and lubrication chart ...........6-3
Removing and installing cowlings and panels .......6-6
Checking the spark plugs ......................................6-9
Engine oil and oil filter cartridge ...........................6-12
Chain drive oil ......................................................6-15
Coolant ................................................................6-17
Cleaning the air filter element ..............................6-19
Adjusting the carburetors .....................................6-21
Adjusting the engine idling speed ........................6-21
Adjusting the throttle cable free play ....................6-22
Adjusting the valve clearance ..............................6-22
Tires .....................................................................6-23
Cast wheels .........................................................6-25
Front and rear brake levers .................................6-25
Checking the front and rear brake pads ..............6-26
Checking the brake fluid level ..............................6-27
Changing the brake fluid ......................................6-28
Checking and lubricating the throttle grip
and cable ...........................................................6-29
Lubricating the front and rear brake levers ..........6-29
Checking and lubricating the centerstand and
sidestand ...........................................................6-29
Checking the front fork .........................................6-30Checking the steering ..........................................6-31
Checking the wheel bearings ...............................6-31
Battery .................................................................6-32
Replacing the fuses .............................................6-34
Replacing a headlight bulb ..................................6-35
Troubleshooting ...................................................6-36
Troubleshooting charts ........................................6-37
6
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6-3
PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU03685
Periodic maintenance and lubrication chartPeriodic maintenance and lubrication chart
NOTE:
8 8
The annual checks must be performed every year, except if a kilometer-based maintenance is performed instead.
8From 50,000 km, repeat the maintenance intervals starting from 10,000 km.
8Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and
technical skills.
NO. ITEM CHECK OR MAINTENANCE JOBODOMETER READING (× 1,000 km)
ANNUAL
CHECK
1 10203040
1
*Fuel line•Check fuel hoses and vacuum hose for cracks or damage.√√√√ √
2
*Fuel filter•Check condition.√√
3 Spark plugs•Check condition.
•Clean and regap.√√
•Replace.√√
4
*Valves•Check valve clearance.
•Adjust.Every 40,000 km
5 Air filter element•Clean.√√
•Replace.√√
6
*V-belt case air filter
elements•Clean.√√
•Replace.√√
7
*Front brake•Check operation, fluid level and vehicle for fluid leakage.
(See NOTE on page 6-5.)√√√√√ √
•Replace brake pads.Whenever worn to the limit
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6-9
PERIODIC MAINTENANCE AND MINOR REPAIR
6To install the cowling
1. Place the cowling in the original
position, and then install the
screws and bolts.
2. Install panels C and E.
EAU03816
Checking the spark plugsSpark plugs, checking
The spark plugs are important engine
components, which are easy to
check. Since heat and deposits will
cause any spark plug to slowly erode,
the spark plugs should be removed
and checked in accordance with the
periodic maintenance and lubrication
chart. In addition, the condition of the
spark plugs can reveal the condition
of the engine. Cowling C
To remove the cowling
1. Remove the cowling bolts.
2. Remove the battery cover by
removing the screws.
3. Pull the cowling off.
To install the cowling
1. Install the battery cover by
installing the screws.
2. Place the cowling in the original
position, and then install the
bolts.
1
2
1. Bolt (×2)
2. Screw (×3)
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6-11
PERIODIC MAINTENANCE AND MINOR REPAIR
6To check the spark plugs
1. Check that the porcelain insula-
tor around the center electrode
on each spark plug is a medium-
to-light tan (the ideal color when
the scooter is ridden normally).
2. Check that all spark plugs
installed in the engine have the
same color.
NOTE:
If any spark plug shows a distinctly
different color, the engine could be
defective. Do not attempt to diagnose
such problems yourself. Instead,
have a Yamaha dealer check the
scooter.
3. Check each spark plug for elec-
trode erosion and excessive car-
bon or other deposits, and
replace it if necessary.
NOTE:
If a torque wrench is not available
when installing a spark plug, a good
estimate of the correct torque is
1/4–1/2 turn past finger tight.
However, the spark plug should be
tightened to the specified torque as
soon as possible.
4. Install the spark plug cap. To install a spark plug
1. Measure the spark plug gap with
a wire thickness gauge and, if
necessary, adjust the gap to
specification.
2. Clean the surface of the spark
plug gasket and its mating sur-
face, and then wipe off any grime
from the spark plug threads.
3. Install the spark plug with the
spark plug wrench, and then
tighten it to the specified torque.
a
a. Spark plug gap
Specified spark plug:
CR7E (NGK)
Spark plug gap:
0.7–0.8 mm
Tightening torque:
Spark plug:
12.5 Nm (1.25 m·kgf)
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PERIODIC MAINTENANCE AND MINOR REPAIR
6
EAU02990
Troubleshooting chartsTroubleshooting charts
Starting problems or poor engine performanceEW000125
w
Keep away open flames and do not smoke while checking or working on the fuel system.
Check the fuel level in
the fuel tank.
1. FuelThere is enough fuel.
There is no fuel.Check the compression.
Supply fuel.
The engine does not start.
Check the compression.
Operate the electric starter.
2. CompressionThere is compression.
There is no compression.Check the ignition.
Have a Yamaha dealer
check the vehicle.
Remove the spark plugs
and check the electrodes.
3. IgnitionWipe off with a dry cloth and correct the
spark plug gaps, or replace the spark plugs.
Have a Yamaha dealer check the vehicle.
The engine does not start.
Have a Yamaha dealer
check the vehicle.
The engine does not start.
Check the battery.
Operate the electric starter.
4. BatteryThe engine turns over
quickly.
The engine turns over
slowly.The battery is good.
Check the battery lead connections,
and charge the battery if necessary.
Dry
WetOpen the throttle halfway and operate
the electric starter.
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7-4
SCOOTER CARE AND STORAGE
7
Storage
Storage
Short-term
Always store your scooter in a cool,
dry place and, if necessary, protect it
against dust with a porous cover.
ECA00015
cC
8
8
Storing the scooter in a poorly
ventilated room or covering it
with a tarp, while it is still wet,
will allow water and humidity
to seep in and cause rust.
8 8
To prevent corrosion, avoid
damp cellars, stables (because
of the presence of ammonia)
and areas where strong chemi-
cals are stored.
Long-term
Before storing your scooter for sever-
al months:
1. Follow all the instructions in the
“Care” section of this chapter.
2. Drain the carburetor float cham-
bers by loosening the drain bolts;
this will prevent fuel deposits
from building up. Pour the
drained fuel into the fuel tank.
3. Fill up the fuel tank and add fuel
stabilizer (if available) to prevent
the fuel tank from rusting and the
fuel from deteriorating.
4. Perform the following steps to
protect the cylinders, piston
rings, etc. from corrosion.a. Remove the spark plug caps
and the spark plugs.
b. Pour a teaspoonful of engine
oil into the spark plug bores.
c. Install the spark plug caps
onto the spark plugs, and then
place the spark plugs on the
cylinder head so that the elec-
trodes are grounded. (This will
limit sparking during the next
step.)
d. Turn the engine over several
times with the starter. (This
will coat the cylinder walls with
oil.)
e. Remove the spark plug caps
from the spark plugs, and then
install the spark plugs and the
spark plug caps.
EWA00003
w
To prevent damage or injury from
sparking, make sure to ground the
spark plug electrodes while turn-
ing the engine over.
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INDEX
F
Front and rear brake levers ..................6-25
Front and rear brake pads, checking ....6-26
Front fork, checking ..............................6-30
Fuel ......................................................3-10
Fuel consumption, tips for reducing .......5-3
Fuel gauge .............................................3-4
Fuel tank cap ..........................................3-9
Fuses, replacing ...................................6-34
H
Handlebar switches ................................3-6
Dimmer switch .....................................3-6
Engine stop switch ...............................3-7
Hazard switch ......................................3-7
Horn switch ..........................................3-7
Pass switch ..........................................3-6
Start switch ..........................................3-7
Turn signal switch ................................3-7
Headlight bulb, replacing ......................6-35
Headlight variations ................................3-8
Helmet holder .......................................3-13
I
Identification numbers ............................9-1
Ignition circuit cut-off system ................3-15
Indicator lights ........................................3-2
High beam indicator light .....................3-3
Oil change indicator light .....................3-2
Turn signal indicator lights ...................3-3
V-belt replacement indicator light ........3-3K
Key identification number .......................9-1
M
Main switch/steering lock .......................3-1
Model label .............................................9-2
P
Parking ...................................................5-4
Part locations ..........................................2-1
Periodic maintenance and lubrication
chart .....................................................6-3
Pre-operation check list ..........................4-1
R
Rider backrest, adjusting ......................3-12
S
Safe-riding points ...................................1-2
Seat ......................................................3-11
Self-diagnosis device .............................3-6
Sidestand .............................................3-14
Spark plugs, checking ............................6-9
Specifications .........................................8-1
Speedometer unit ...................................3-4
Starting off ..............................................5-2
Starting the engine .................................5-1
Steering, checking ................................6-31
Storage ...................................................7-4
Storage compartments .........................3-14A
Acceleration and deceleration ................5-2
Air filter element, cleaning ....................6-19
Anti-theft alarm (optional) .......................3-6
B
Battery ..................................................6-32
Brake fluid level, checking ....................6-27
Brake fluid, changing ............................6-28
Brake lever, front ....................................3-9
Brake lever, rear .....................................3-9
Brake levers, lubricating .......................6-29
Braking ...................................................5-3
C
Carburetors, adjusting ..........................6-21
Care ........................................................7-1
Centerstand and sidestand, checking and
lubricating ..........................................6-29
Chain drive oil .......................................6-15
Clock ......................................................3-5
Conversion table ....................................8-5
Coolant ..................................................6-17
Coolant temperature gauge ....................3-5
Cowlings and panels, removing and
installing ...............................................6-6
E
Engine break-in ......................................5-4
Engine idling speed ..............................6-21
Engine oil and oil filter cartridge ...........6-12
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